Mattress, cushion or the like



April 18, 1961 D. KRAKAUl-:R

MATTRESS, CUSHION 0R THE LIKE Filed Dec. 26. 1957 IN VEN TOR. Dam elKrakauer Fig. I

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l OGOGOGQG PO o@ @o Qhwsooo @DFMDD GD h A TTORNE'Y (tijd MATTRESS,CUSIHON R THE LIKE Daniel Krakauer, Great Neck, N.Y., assignor to KayManufacturing Corp., Brooklyn, N.Y., a corporation of New York FiledDec. 26, 1957, Ser. No. 705,218

13 Claims. (Cl. 5-345) This invention relates to mattresses, cushionsand the like, and particularly to the means for arranging and connectingthe inner resilient cushioning elements thereof to form an inner springunit or the finished mattress.

The invention contemplates the provision of a light weight ventilatedmattress or innerspring unit adapted for quick and easy cleaning andrequiring little or no padding or insulation, yet providing adequatesupport and yielding sufciently for comfort.

The invention further contemplates the provision of a mattress orcushion or innerspring unit therefor made largely or entirely of plasticmaterial and having a resilient and liexible plastic grid-like top andbottom with integrally molded means for arranging and connecting therespective tops and bottoms of suitable interior resilient cushioningelements and thereby eliminating the need for border wires, helicals,clips, rings and the like fastening means, and the need for therelatively thick padding and covering heretofore deemed essential.

The various objects of the invention will be clear from the descriptionwhich follows and from the drawings, in which- Fig. 1 is a top plan viewof a mattress or inner unit embodying the invention, the pattern of theopenings shown in a portion of the top being continued throughout theentire top to form a grid-like member.

Fig. 2 is an elevational View thereof.

Fig. 3 is a fragmentary enlarged vertical sectional view thereof showinghourglass springs as the cushioning elementsand the thickened lugs andborders,

Fig. 4 is a somewhat similar sectional view of a resilient grooved lugfor holding the end coil of an hourgiass spring or the like to theplastic top or bottom.

ig. 5 is a similar view of the same showing the end coil inserted intothe lugr and showing in dotted lines how the sides of the lug 'arespread apart to permit the passage of the wire coil into the groove.

Fig. 6 is a similar View of a modiiied form of the grooved holding lug,showing in dotted lines the operative bent over and heat-sealedpositions of the sides of the lug.

Fig. 7 is a fragmentary vertical sectional view of a modiiied form ofthe cushioning element.

Fig. 8 is a similar view of another modified form of the invention inwhich suitably shaped resilient plastic members constitute thecushioning elements.

Fig. 9 is a similar view of still another modiiied form of the inventionin which pre-shaped sinuous or zig-zag wire springs constitute thecushioning elements.

in all the forms of the invention, it is intended that a resilientexible top as lil, molded or otherwise suitably formed, preferably of asingle piece of non-foam plastic material, be used as the sole means forarranging and connecting the tops of the interior cushioning elements as11 regardless of the shapes or materials of which such elements aremade, and that a similar or identical bottom as 12 be used similarly asthe sole means to arrange and to connect the bottoms of such elements.The mat- ...ited States Patent v fo lc@ tress or inner spring unittherefore consists merely of the one piece plastic grid-like top, thesimilar bottom and the cushioning elements therebetween, no additionalfastening elements being essential and the top 10 and bottom 12 beingunconnected except by the springs. For the purpose of thisspecification, the resilient cushioning elements of whatever form willbe termed generally springs," and the mattress, cushion or inner unitwill be termed the mattress Since the top 10 and bottom 12 aresubstantially identical, the description of one will suffice for both.

As shown in Figs. l-3, the top 10 determines and is coextensive With thelength and width of the mattress and is of substantially uniformthickness but is thickened where necessary or desirable, as for example,to provide a reinforced and stiffened border or marginal portion aslaround the periphery thereof and to provide suitable integral securinglugs for the springs 11 which are relatively small and closely spaced.Said top is preferably made-of suitable moldable synthetic plastic whichis tough and stiff enough to take the stresses put thereon yet isilexible and resilient enough to provide comfortable support for thebody of the user, such as polyethylene or a vinyl resin. Numerousopenings in any desired pattern, determined largely by the size, shapearrangement and spacing of the springs, are also made in the top andserve not only to ventilate the interior of the mattress, but also toincrease the yieldability and flexibility of the top as Well as toeconomize in material, to reduce the weight of the'mattress and toprovide access to the springs and securing lugs for purposes ofassembly, replacement and repair. If the spring spacing is to be variedat different areas of the mattress, the pattern of the openings isaccordingly varied at such areas. Such variations of the pattern mayalso be caused by the use of spring end portions of dierent dimensionsor shapes at dierent parts of the top, or of differences in the types ofsprings ernployed. As shown in Fig. 1, the pattern of the openingsillustrated provides an annular relatively stiff solid portion 15 withradiating arms 16 and a diametrical arm 17.

Suitable outstanding and circumferentially spaced apart lugs as 20(Figs. 345) each integral with the remainder of the top and providedwith a groove 21, are conveniently arranged, as for example, at thecircular portion 15 for holding in place the end coil 22 of thehourglass spring 23 which constitutes one form of the cushioning elementor spring. Said spring 23 or other cushioning element acts to secure thetop 10 movably in upward spaced parallel relation to the bottom 12 whenthe respectiveend coils 22 thereof are secured to Vsaid top and bottom.The spring is also biased to urge the top and bottom apart.V As thecushioning elements at the areas under pressure, contract and expandunder the pressure, the adjacent parts of the top move toward and awayfrom the bottom.

The means for arranging and securing the end coils of the hourglassspring 23 in place may take various forms. As shown in Figs. 4 and 5,two or more relatively short lugs 20 are used. The entrance 25 to thegroove 21 of the lug is somewhat constricted and is of lesser width thanthe diameter of the wire of the end coil 22 which the groove is designedto receive. Said coils are forced into the grooves individually orcollectively as is found convenient, with a snap action. As shown inFig. 5, the resilient sides 26 of the groove spread apart to the dottedline positions thereof, enlarging the constricted passage 25 temporarilyand allowing the end coil to pass and'to enter the groove. The passagecloses to its initial position after the end coil has snapped intoplace. Suitable adhesive or cement may be employed to aid in holding theend coil in the groove.

As shown in Fig. 6, the groove 27 ofthe lug 2,8 has substantiallyparallel or inwardly divergent sides 29 so that the end coil 22 is-readily inserted into the groove with or withoutV the use of adhesive.Thereafter the sides of the groove are heated and when softened, arepressed toward each other into the positions shown by the dotted line ofFig. 6 to seal the groove entrance and to secure the end coil thereinto.

By selecting appropriate springs of the proper sizes and shapes andcontrolling the spacing of the springs, any desired resistance to theweight of the user, and the desired supporting eiect within a widerangemay be imparted to a given area of the mattress. The exibility andresilience of any area of the mattress may also be. controlled byregulating the thicknesses of the top and bottom at such area. Since themattress is substantially symmetrical about a horizontal planemidwaybetween the top and bottom, said top and bottom may be molded in thesame molds and become interchangeable. By coating the springs with asuitableprotecting coating to prevent corrosion, such as Ypaintorplating, the mattress may-then readily be cleaned by hosing or sprayingor other Washing method. In view of the numerous openings in, and thespacing apart of, the top and bottom and the consequent open andunobstructed sides and ends, good ventilation is obviously attained.Since the edges of all the openings and of the sidesv and ends of thetop and bottom are well rounded, the mattress may be used by itself andWithout padding, covering or ticking, and with or without the-usualremovable mattress quilt or pad used to protect against thepressure oftufting buttons. Furthermore, in view kof Ythe minimum amount of metaland the absence of metallic fastening means, the mattress is extremelylight, Veasy to manipulate and relatively inexpensive to ship. Y'

As has been indicated, the springs Vmay take a variety of forms otherthan those of the hourglass type.v In Fig. 7 is shown the hollow rubbercylinder A30 as Ythe spring, the upper and lowerV ends of the cylinderbeing secured in the lugs 31 projecting inwardly from theetop andbottom. The spring 32V shown in Fig. 8 is of a suitable light weightresilient and exible synthetic.plas tic material of the requisitethickness and shape to urge the top and bottom apart, and to yield tothe desired extent under the pressure of the body of the user. As shown,said spring 32 is preferably symmetricalV about a horizontal planemidway between its ends, the entire mattress also being symmetricalabout such plane so that it can be used in the customary manner witheither the top or bottom on top. The lugs 33 forming integral parts ofthe top and bottom hold the upper and lower ends of the springs 32 inplace.

In Fig. 9 the spring 34 is made of zig-zag or sinuous wire of a wellknown type used in upholstered furniture and automobile seats, and has apairy of similar arched portions 35, 36 meeting at a relativelyV sharpbend or apex 37. Those cross bars extending from loops at the ends ofthe springs as at 38, `39k are secured to one Vof the connecting membersof the mattress such as the top 10, while the cross bar at the apex 37is secured to the opposed connecting member such as the bottomA bysuitable lugs as 40. As shown, the alternate springs 34, 34a arereversed in relative positions, but owing to the arched shapes of theportions 35, 36, allof the springs Y urge the top and bottom apart butyield as required under the weight of the body at any area of themattress.

Where heat sealing of the holding lugs is required, access to the lugsin the assembly of the parts may readily be had through the variousopenings in the top and bottom adjacent to said lugs and by a suitabletool. The openings and the open sides and ends also make it easy toclean the mattress by Washing or dusting. The openings have roundededges and are small enough to avoid material indentation of the body ofthe user and hence need little covering, if any.

While certain specific forms of the invention have herein been shown anddescribed, various obvious changes may be made therein without departingfrom the spirit of the invention defined by the appended claims.

I claim:

l. In a mattress, a one piece top of synthetic exible and resilientnon-cellular and non-textile lightweight plastic resinous material andof the length and width of the mattress constituting an incompressiblebut yieldt able support for the body of a user, a similar bottomarranged below the top and movable toward and from the top to provide anunobstructed space therebetween at the sides and ends of the mattress,'means on and integral With the inner surfaces of said top and bottomand constituting the sole means for holding in place and arranging inrows cushioning elements arranged therebetween and urging said top andbottom apart, and cushioning elements each independent of the other ele`ments and unconnected thereto except by said top and bottom bridging thespace between the top and bottom and engaged by said means, the materialbeing thermoplastic, and said means comprising lugs on the inner facesof the top and bottom adapted to engage, encase and embrace the materialat the respective end portions of the elements, there being a groove ineach lug between the inner and outer sides of the lug receiving the endportion of an element.

2. A one piece moldable spring-holding member for use as the top orbottom of a mattress or the like having inner resilient cushioningelements connected solely by said member, the member determining thelength and width of the -mattress and having a plurality of spacedopenings therein arranged in a grid-like pattern determined by theshapes, sizes and positions of the inner cushioning elements of saidmattress, said member being molded of a light-weight synthetic toughexible and noncellular substantially in elastic and resilient plasticmaterial and being self-supporting and self form-retaining andsufficiently stii to prevent displacement of said elements andsufficiently flexible and resilient to conform to the shape of and tosupport the body of the user and adapted for connection to the ends ofsaid elements and to arrange and to hold said ends in rows.

3. The moldable member of claim 2, the Vmarginal portions andintermediate selected portions of said member between the openings beingthicker than the remainder thereof, and means integral with the memberand constituting the sole means for securing the ends of the .cushioningelements to the inner face of the member, the edges of the openingsbeing rounded to avoid cutting into the body.

4. The moldable member of claim 2, the major areas of the member beingof a single layer of material, the material between the openingscomprising diagonally arranged arms of substantially rectangularoutline, similar rectangular arms parallel to the side edges of themember and similar varms parallel to the end edges of the member, theedges of the opening being rounded.

5. A Alightweight ventilated mattress comprising a single relativelystii top sheet of a substantially incompressible self-sustaining andself form-retaining non-cellular tough flexible vand resilient syntheticplastic material vother than textile, elastic, and foam materials, saidsheet being of substantial thickness and having integral stili dependinglugs each having an inner side and an outer side and being provided witha groove between said sides, a single bottom sheet substantiallyidentical with the top sheet and in parallel inverted spaced relationthereto, and a plurality of spaced apart resilient cushioning elementseach of substantially uniform thickness and each in spaced relation to,independent of and unconnected -to the remaining elements except by saidtop and bottom sheets, the width of the groove of each -lug being ofsubstantially said uniform thickness and receiving and encasing the endportion of an element to hold said portion permanently therein, the'lugs constituting the sole means for arranging the elements and forsecuring the elements to the top and bottom sheets and against relativedisplacement with respect to each other, the side and end edges of thesheet being spaced away from the other sheet to provide a spacetherebetween communicating at all times with the spaces between theelements.

6. The mattress of claim 5, at least one of the sheets having amultiplicity of openings of different shapes completely therethrough andforming a predetermined pattern and suiciently large to permit accesstherethrough to the elements, those parts of the sheet between theopenings being solid and smooth.

7. The mattress of claim 5, the groove of each lug being constricted atthe entrance thereto to a width slightly less than the thickness of thematerial of which the element is made whereby the end portion of theelement may be forced into the groove with a snap action and heldtherein against removal under the usual stresses of use.

8. The mattress of claim 5, the material of the lugs being heat scalableand the entrance to the groove being substantially closed after the endof the element has been inserted thereinto to retain said endpermanently therein.

9. A mattress unit consisting of a light-weight, tough, dense, exible,substantially inelastic, incompressible and self-form-retaining,non-cellular and non-textile premolded plate-like top of sheet-likeplastic material having a plurality of openings therethrough, the topbeing of a single thickness of material, a similar one piece bottom inparallel spaced relation to and unconnected to the top throughout thearea thereof except by the elements hereinafter mentioned, a pluralityof initially unconnected and independent spring elements extendingseparately between the top and the bottom, connecting means integralwith and projecting downwardly from the top constituting the means forarranging the otherwise unconnected upper ends of vthe elements inpredetermined spaced relation to each other, said means also securingthe elements to the top and means integral with and projecting upwardlyfrom the bottom arranging and securing the lower ends of the elements insimilar spaced relation to the bottom, each of said means being arrangedadjacent the openings of the top and bottom respectively. i

10. Means for arranging in rows the opposite ends of uprightindependent, spaced apart springs in a mattress and for maintaining saidends in said rows under the stresses on the mattress resulting from use,said means comprising a self form-retaining, plate-like, non-foam topsheet of synthetic resin coextensive with the mattress, said sheet beingsuiciently stil to prevent displacement of said spring ends after saidends have been assembled to the sheet, said sheet being suicientlyflexible and resilient to support and conform to the body of a user, andbeing of a single variable thickness of material substantially resistantto penetration by a free end of a wire spring, a similar bottom sheet indownward spaced relation to the top sheet and unconnected thereto exceptby the springs thereby to provide an interior space between the top andbottom unobstructed except by said springsand communicating with theexterior of the'mattress at the sides and ends thereof and meansintegral with and projecting from the sheets for securing the endportions of each of the springs to the adjacent sheet against movementrelatively to said sheet and against movement Vtransversely relativelyto the corresponding end portions of the remaining springs whilepermitting relative lateralV movement of said end portions of thesprings.

11. Means for arranging in rows the opposite ends of upright springs ina mattress and for maintaining said ends in said rows under the stresseson the mattress resulting from use, said means consisting solely of anonfoam top sheet of synthetic resin coextensive with the mattress, asimilar bottom sheet in downward spaced relation to the top sheet andunconnected thereto except by the springs thereby to provide an interiorspace between the top and bottom unobstructed except by said springs andcommunicating with the exterior of the mattress at the sides and endsthereof and means integral wit-h and projecting from the sheets forimmovably securing the end portions of the springs to the sheets, eachof said sheets having openings therein adjacent the projecting means,through which openings the springs are accessible, the openingscommunicating with said space, and a multiplicity of spaced apartindependent springs unconnected to each other except by the integralprojecting means of the top and bottom sheets.

12. A plate-like spring-arranging and spring-holding self form-retainingmember of a light-weight, tough, exible, non-cellular-and non-textileplastic material, the member being yieldable and suiiciently stii forthe direct support of the body of a person, the member having aplurality of spaced apart openings therein, the thickness of the memberbeing greater at the peripheral edges of selected openings and at theperipheral edges of the member than between the openings, said edgesbeing rounded to avoid excess indentation of the body of the personsupported by the member, and means projecting inwardly from the memberadjacent the openings for arranging in place adjacent the inner face ofthe member and for securing thereto, a multiplicity of spaced apart rowsof spaced apart and independent springs.

13. A plate-like, yieldable, spring-arranging, springholding andspring-uniting member for use as the top or bottom of a mattress havingindividual, independent, resilient, inner cushioning elements, and meansprojecting inwardly from said member for connecting the correspondingends of the element, the member having a plurality of spaced apart rowsof spaced apart openings therethrough arranged in a pattern determinedby the position of said means, the member having suticient dimensionalstability to control and determine the length and width of the mattress,and being molded of a lightweight, tough, flexible, non-cellular andresilient plastic material, and being self form-retaining and suicientlystili to prevent displacement of said elements and to support the bodyof a user, the member being suliciently resilient to return to thenormal plate-like shape thereof on the release of the load thereon, andybeing ofV a single thickness of material, the edges of the openingsbeing permanently rounded.

References Cited in the le of this patent Y UNITED STATES PATENTS2,008,185 Pittoni July 16, 1935 2,235,554 j Hopkes et al. Mar. I8, 19412,267,472 Lieberman Dec. 23, 1941 2,309,438 Burisch Jan. 26, 19432,425,728 Cobb Aug. 19, 1947 `2,610,334 Piliero Sept. 16, 1952 2,784,773Rowland Mar. 12, 1957 FOREIGN PATENTS 335,571 Great Britain Sept. 22,1930 397,140 Great Britain 1.-.,-.. Aug. 10, 1933 794,573 France Dec. 1,1935 177,291V Netherlands Dec. 15 1955

